GS41 upgrades and repairs
Walt, the deck repair involves removing one of the fiberglass skins (top or bottom),removing the wet/delaminated balsa core, installing new core and glassing the skin back in place. I did our cabintop core by removing the lower skin. This is initially more difficult but it avoids the extensive cosmetic repairs that the deck surface would require if the top skin were removed and reinstalled. A good tool for cutting the skin is a Rotozip with a 1/8" carbide bit. Screw temporary battens near the cut lines to guide the tool, as it is hard to control by free hand. The new core is two layers of 1/4" marine ply, sealed and laminated with West epoxy. Two thin layers instead of a single 1/2" are easier to bend to match the curve of the cabintop. If you are doing flat areas like the side deck you could probably use the 1/2" ply. Also got rid of the biggest leak source, the original teak mast collar that was just screwed to the deck with sheet metal screws. The new collar is welded stainless plate, bedded and thru-bolted.The rudder post is a solid 1.75"d. stainless shaft with no visible wear or corrosion, even in the packing gland area, so I'm not too worried about it. But I had to replace the heavily corroded support bridge which is made of mild steel. This bridge is the square frame directly under the steering quadrant and it supports all the weight of the rudder/shaft/quadrant system. If it should fail, the rudder would drop to the shoe at the bottom of the skeg and probably jam. While I had the system apart I installed new packing, 3 rings of the 7/16" teflon impregnated stuff. This looks like it would be impossible to do with the support bridge and quadrant in place. Let me know if you'd like additional details.